Switch assembly



March 4, 1958 W. J. KELLEIGH SWITCH ASSEMBLY Filed July :5, 1953 j j'j'g i? 3 She ai N ets-Sheet l ffy-z ai mz/4 15K??? f6.5

Wm WM March 4, 1958 w. J. KELLEIGH 2,825,778

' SWITCH ASSEMBLY Filed July 5, 1955 3 Sheets-Sheet 2 jff j'? if? ,905 jig 15.4

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SWITCH ASSEMBLY Filed July 3. 1953. 5 sheets-sheet s LJ/dfl, 50i/Jaa .mi 51) 714.4 5%?)1/ figg 15'? frzyezzw" W/ WMM/Kaz Ip L7 @yz/W wam @s SWITCH ASSEMBLY Application July 3-1953, Serial N 365,855 22v Claims. (Cl. `200-67) This invention relates to switch .assemblies of the type carrying a small spring switch within a housing that is provided withl an actuatingdevice for the switch and can be convenientlymountedon a :supporting structure.

lt is one of the principal objects of the invention to provide switching apparatus of theabove type, suited for use in a variety of applications requiring compact, light weight and durable construction.

Another object is to provide within a housing of versatile construction a direct acting .switch without inherent characteristics of bounce, which has no mechanical lost motion causing an .uncontrollably vvariable time delay as in conventional snap switches, the .same housing being however fully practical .to accommodate switches ofthe snap action type.

` 'Further objects are to provide a switch assemblywhich permits mounting in a variety of ways making it particularly adaptable for many .applications and combinations with other apparatus, which permits avariety of good electrical connections which may or may not be used as supports, and which will accommodate either a direct acting slow spring switch or, without alteration or adaptation, a switch ofthe snap action type. The first mentioned type of switch assembly can be with safety applied to apparatus where precision of electric timing is required and where it is important to insure contact transfer with maximum spring pressure up to the actual make or break. `If the assembly is used to accommodate a'snap action switch, either .snap action `of ythe spring return type or of the reset type can be provided without modification ofthe housingthe spring'blades and actuating elements being in either case rigidly secured to the housing in a manner providing reduction kin electrical resistance while providing great mechanical strength and a prolonged life.

The same housing and stationary switch contact springs can be used in either case, with .the consequent saving in manufacture, manipulation and installation.

Still further objects are to provide a switch assembly which can be easily mounted on panels or frames or joined to companion switches, and has exceptionally well spaced and accessible terminals which, if desired, can be used as mounting supports.

An electric switch assembly according to the invention comprises an elongated base `formed of insulating material, a cover of' insulating `material fitting the base and dening with the base an enclosed cavity, holes extending through thebase and the cover respectively, at each vend and intermediate thereof, three internally threaded hollow rivets, one in each of the holes of the base,`switch contact members `fastened to the base within the cavity by means'of the rivets, and screws extending through the end holes of the cover to engage the internal threads of the'rivets in the corresponding holes of the base, for fastening the cover to the base.

.ln yanother aspect of the invention, the switch assembly comprises a movable yswitch Contact member (either of the slow action type or a composite snap action contact nited `States Patent O member) fastened to or-with one rivetvin one of the end holes of the base, and essentially stationary contact leaves or springs fastened to or with the other rivets, oneither side. of the movable member.

ln a further aspect, the internally threaded hollow rivets receive metal-or insulatingscrews joining base and cover, for mounting the assembly, for fastening terminal devices, and for receivingmovable parts-such as actuators.

.Other objects and aspects of vnovelty will appearin addition to those contained'iny the above summary of/ the invention indicating its nature and substance including some-of itsobjects kfrom'theherein'presented outline of its mode of operation and practical possibilities together with a description of iseveral typicalembodiments illustrating its novel characteristics. Theserefer to drawings in which Fig. vl is the .plan' view of afswitch assembly according to theinvention;

Fign 2 is a cross section, partly along 2 2 of Fig. r3*;

Fig. 3 is a cross section on 3 3 of Fig. 1;

Fig. 4 isa plan View of the'base with the switch according to Fig. 3;

Fig. 5 is a plan'viewof Athe insideofthe cover according to Figs. l to 3;

Fig. 6 is a -plan .view similar to Fig. 4 without the switch;

.,Fig. 7 isa bottom lview of the base-according to Fig. 1 to 4 and 6;

Fig. S-,is a.section.on18 8 of Fig. 6;

Fig. 9 is a section on 9 '9of Fig. 6;

Fig. l0 is a 'front .elevation of the base according to Figs. l to 9;

Fig. 1l is Yanaxial -section-througha hollow rivet such asshown in Fig. 3;

Fig. l2 is the bottom view, similar to Fig. 7, ofthe base, with mounting terminals;

Fig. 13 isa side elevation, partly in section on lines 3 3 of Fig. l, through a .switch assembly mounted with studs on a panel;

Fig. 14 is an elevation and section similar to Fig. 13, of a switch assembly Ymounted with the aid of auxiliary holes of the base;

Fig. l5 is a section on 3 3 of Fig. 1 through the cover and part of the base, similar to Fig. 3, showing lin addition an actuator spring;

Fig. 16 is a section on 3 3 of Fig. l through part of the cover and through an actuator mount;

Fig. 17 is a section on 3 3 of Fig. 1, similar to Fig. 3, but containing a reset type .snap action switch in one position;

Fig. 18 is a section similar switch in the other position;

Fig. 19 is a section similar to Figs. 17 and 18 but containing a snap action switch of the spring return type in intermediate position;

Fig. 20 is a section similar to Fig. 19 but with the switch in normal position; and

,Fig. 21 is a plan view of a snap type shown in Figs. 17 to 20.

In Figs. l to 10, the switch assembly 30 is shown as having an essentially parallelepipedal housing 31 made of moldable insulating material, with a bottom part or base 32 and a top part or cover 33.

The outer surface of the bottom part 32 is essentially to Fig. 17 but with the spring element of the smooth with the exception of two ribs or barriers 35,

36 (Figs. 3, 7) on the outside of the bottom Wall. The inside of the bottom part has four levels relatively to the circumferential rim 40 which fits the corresponding rim S0 of the top part 33. The highest and next to highest levels are formed by the extensions 41 and 42 which are higher than 40 (Figs. 3 and 9), and the two lower levels 3 are formed by surfaces 43 and 45. At a level intermediate 43 and 45 is provided a three sided recess 44 (Figs. 6 and 8) in surface 43. The extensions 42 and 41 have comparatively low lips or edge ridges 51, 52, 53, 54 which are especially well shown in Figs. 6, 9 and 10.

The `bottom part or base 32 has three transverse perforations 61, 62, 63 (Figs. 6, 7) and two lateral perforations 65, 66 (Fig. 3). The bottom surface of the base 32 is provided with shallow lateral recesses 71, 72 at the opening of each hole 61, 62, 63, as clearly indicated in Figs. 2 and 7 tor9. These have the purpose of receiving therears or lugs 153, 154 of the rivets in order to lock them as will be described hereinbelow with reference to Fig. l1.

The top part or cover 33 of the housing 31 has a groove 81 (Figs. l, 2, 3) running the entire length of its upper surface, and on the inside (Fig. it has two ledges denning three symmetrical levels indicated at 85; 86, 87;

88,89. The top portion 33 has two transverse holes 91, 92 (Figs. 3, 5) corresponding to and having the same diameter as holes 61 and 62 (Figs. 6, 7) of the bottom part 32. If it is desired to make the cover especially strong, ledges 86 and 87 can be merged into a single surface, in which case only two levels, namely 88--89 and 8'6-87 will be present.

The toppart 33 has also a center hole 93 (Figs. 3, 5)

for the shank of an operator 181 to be described hereinbelow and two smaller holes 95 and 96,v for auxiliary rivets or screws. cover part, within the groove 81, is a boss 101 surrounding hole 93, and two counter bores 102 and 103 for holes 91 and 92. Slots 10S lead outwardly fromfthe level of the counterbores, vand more shallow recesses'106 opening into counter vbore 102, surround holes 95 and 96, as shown in Figs. l to 3.

The level 43 of the base 32 has a circular recess 121 (Fig. 6) which can be used to receive an assistance spring to be discussed hereinbelow.

In the embodiment shown in Figs. 3 and 4, the switch assembly contains a slow acting limit switch with two xed contact springs 111, 112 and a movable contact spring 114. The springs 111, 114 are comparatively wide and till the above mentioned recesses between lips 51, 52 and 53 and 54 respectively whereas spring 112 of similar width, ts the shallow recess 44 (Figs. 4 and 6). The switch is assembled by means of special rivets 150 according to Figs. 3 and ll. Prior to assembly, such a rivet has a tubular shank 151, a ange 152, and two lugs 153 and 154 which fit recesses 71, 72 (Fig. 7). It is countersunk at 155 and 156 and has an inside thread 157.` Upon assembly, the end 159 is spun or otherwise expanded over the housing surface which is opposite the flange or head 152, as for example indicated at 160 of Figs. 3 and 4.

A secondary switch spring, also called anvil, marked 115 in Figs. 4 and 15, can be inserted below spring 114. It was found that such an anvil essentially prolongs the life of the switch spring proper 114, releasing the stress on its root near the rivet head 160i. The anvil also assists in returning switch spring 114 into nor mal position. This function is similar to that of spring 185`and either spring or both can be used.

Various screws, bolts or other threaded fastening members can be used for assembling the switch or for fastening it to other construction components. As indicated in Fig. 3, screws 161 and 162 can be used to fasten the top part 32 to the bottom part 32. If desired, they can be used for holding terminal strips 165, 166. Screws 171 and 172 can be used for fastening terminal lugs or strips 173, 174, 175 to the base portion 32 (Figs. 3 and l2). In either case, the hollow rivets establish electric connections between the switch contacts and the terminals. If only the base terminals 173, 174, 175 are used, insulating such as nylon screws are used at 161, 162 or At the upper surface of the top or 4 171, 172, providing a fully insulated cover. sibility is also indicated at 242 of Fig. l5.

Other uses of the hollow rivets will be described hereinbelow. An actuator of suitable shape, indicated at 131 of Fig. 3 can be inserted in the perforation 93 of top part 33. This actuator can have a narrow portion fitting the hole 93, and a wider portion 183 with a round tip that normally rests on movable contact spring 114. v

To operate a switch of this type, actuator 181 is depressed manually or by means of auxiliary gear such as will be described hereinbelow. r Contact 114-'is thus transA ferred from spring 111 to spring 112. Upon release of the actuator, contact is reestablishedl between 111 and 114. 1f single throw action is sufficient, one of the stationary contact springs 111 or 112 is omitted, in which case the assist springs mentioned below can be advantageously used. A spring can be lodged in recess 121 (Figs.v 3 and 6), and a spring 186 can be similarly inserted into the inside opening of the rivet in hole 62. Spring 165, upon actuator 181 being depressed, changes the leverage of contact spring 114 during operation, thus providing excellent wiping contact with the well known advantages. Spring 136, insulated from its rivet by a button 187 if desired, can serve as an assist spring for `Contact blade 114, helping to push the head 153 towards the cover 33, vwhen This posthe actuator 181 is in normal, non-depressed condition elements such as actuator 312 of the embodiment according to Figs. 17 and 18.

The spring 186 or an element similar to the .button 321 of'Figs. 18 to 20 with or without rivet, can Serve as a stopv for switch blade 114, if blade 112 is omitted for purposes of single throw switching.

It will 'be noted that the switch contact springs 111, 112 are identical in shape, in the embodiment according to Figs. 3 and 4 as well as in those according to Figs. 17 to 20; this results in considerable savings in tools and assembly work. I

The auxiliary transverse holes 106 (Fig. 3) and the lateral holes 65 to 66 (Fig. 3) serve various purposes, some of which will be described with reference to Figs. 12 to 16.

It will be understood that the hollow internally threaded rivets can be combined with screws, contact elements and terminal members of various types, in various positions, especially the use of insulating screws provides wide adaptability without any structural change, merely by using diterent standard screw components.

Figs. l2 to 16 illustrate the adaptability and versatility of the switch assembly according to the present invention.

Fig. 12 indicates a manner in which the switch assembly 30 can be mounted on an insulated panel 200, by means of supporting terminal strips 201, 202, 203 which are fastened to the switch housing by means of screws 205 engaging the threaded hollow rivets such as 61, 62 and 63 of Fig. 3. The supporting terminals can be fastened to the panel 200 or other supports by means of terminal screws 206 or smaller fastening screws 207.

Fig. 13 shows another Way of fastening a switch assembly of the present type to an insulated panel or other support 220. In this case, the screws 161, 162 of Fig. 3 are replaced by a stud 221 with two nuts 225, 226. The element 220 can be strip-shaped, fitting the groove 81 of the top moulding 33, as indicated in Fig. 13. Needless to say, it may also be a panel in which case it will rest on the two elevated rims on either side of groove 81. The nut 226 serves to fasten a terminal strip to the top part of the housing, connecting this terminal strip tothe fixed switch spring111. .The stud.202serteslthe `4same purposewith regard to movable contact spring11v4. The rterminal for the second, fixed, contact spring 112, may be similar to that shown at 175 of Fig. 3, and indicated with the'same numeral in Fig. 13,

Fig. .14 shows the possibility of fastening a switch assembly 30 to a recessed supporting member such asindicated at 231 and 232, leaving sufficient operating space for the protruding part 182 of Vactuator 181. In this instance, bolts through the small holes `95 and 96 indi.- cated in Fig. are utilized to fasten the top part of the housing to supporting members 231 and 232. The lateral holes 65 and 66 shown in Figs. 3 and 6 can be used in similar manner, for joining or mounting several switch assemblies by means of screws or studs through these holes of several switches or through holes lor slots of suitable mounting members.

Fig. 15 illustrates the mounting of an actuator spring 2741 on the top part 33 of the switch assembly 30, by means of a screw 242 corresponding to screw 161 of Fig. 3. The spring 241 ts the groove 81 (Fig. 1) of the top part and normally touches the protruding portion 182 of the actuator 181. if a contact 111 is usedas indicated in Fig. 15, the screw 242 is preferably made of insulating material such as nylon, Valthough spring 241 is not in electrical contact with any switch member. The spring 241 can be provided with a bearing bracket 245 carrying an oilite roller 246. Suitable actuating equipment such as for example incorporating a cam (not shown) contacting the roller 246 can bemounted on or adjacent to the switch assembly. In that case, the spring 241 can be mounted on the vtop part 33 by means of the auxiliary holes 95 or 96, and an actuator ,frame .or base on the top part of the switch assembly by means of screws 161 and 162.

Fig. 16 shows another type of actuator mechanism comprising a base strip 251 with two side iianges 252 and 253 with holes 25d, 255, the strip corresponding to groove 81 of top 33. VThe two holes 254 and'255 are aligned with holes 91 and 92 of top 33, and screws 161 and 162 are again used for fastening this actuator mechanism to the switch assembly. As indicated in Fig. 16, an actuator pin 261 can be guided in a nipple 262 and a hole 263 of the actuator. Bymeans of a'ange 26S and a spring 266, the actuator pin carries an oilite roller v268, similar to part 246 of Fig. 15. The extension 182 of actuator `181 of the switch assembly reaches into hole 263 and is depressed by the normally raised actuator pin 261 when roller 268 is in Contact with a transmission link,`such`as cam or the armature of a solenoid.

Figs. 17 to 20 indicate 'the possibility of using the switch assembly according to the invention with Va snap-action switch instead of the slow acting switch described above with reference to Figs. 3 and "4.

Referring first to Figs. 17 and 18, a reset snap-action switch 'of the type described and claimed in co-'pending application Serial No. 558,227 of January 10, 195,6, is mounted within the housing 32, 33 by means of rivets 61, 62 and' 63 which correspond exactly to the similarly numbered elements of Fig. 3.' The movable contact element 300 of this snap switch consists of a'frarne member 301 and a spring member 302 as shown in Fig. 21. Spring and frame vare pivoted on two compensating pivot springs 305 and 306 with hooks or sockets 307, 308 respectively, mounted on a bracket 309. The stationary contact springs 111 and 112 correspond to those similarly desig nated in Fig. 3, and are again fastened between the housing and flanges of their rivets 61 and 62. Two actuators 311 and 312 are provided, each having a push-button portion 314 and 315 respectively. The snap switch operating points 317 and 318, accommodated within frame 301, contact the bent spring member 302 in one or the other position as shown in Figs. 17 and 18 respectively. With the snap-switch in the position of Fig. 17, if the actuator 311 is depressed the spring 302 will be bent downwardly ,andthe .framelsnaps upwardly just as soon as the spring bow passes the pivot line dened vby the pivot pointsof hooks 307 and 308. The spring switch thus snaps into the position vshown in Fig. 18, and actuator point 318 rests on the downwardly bent spring member 302. For returning the switch into the previous position, button 312 is pressed and the spring snaps back into the position of Fig. 17.

Figs. 20 and 21 show a spring return snap-action switch incorporated in the switch assembly according to Figs. 1 to 10, replacing the slow action switch shown in Figs. 3 and 4. This embodiment is similar to that shown in Figs. 17 and 19, with the exceptions that a somewhat different spring pivot construction is used and that the actuator 312 is replaced by a resilient stop member such as button 328. The pivot members 316.1, 316.2 are in this instance directly fastened to rivet 63. The snap switch unit proper 320 has a spring'322 which is fixed to the frame 321 at the contact end 323, as shown in Figs. 19 and 20. When the actuator 311 is pressed with the switch in the position of Fig. 19, the spring 322 bending downwardly as shown in Fig. 20 contacts the button 328 which snaps it immediately back into the initial position. Release of button 311 restores the assembly into the position of Fig. 19. Thus one actuating operation of push-button 311 causes a momentary contact transfer from 111 to 112, returning the snap element into normal contact with stationary Contact 111.

The pivot members 305, 306, 316.1, 316.2 of Figs. 1.7 to 21 have the purpose of compensating for the elongation of the spring member 302 or 322 during the snap action. They also provide good wiping cont/act, with the wiping movement of the frame 301er 321 and hence of the movable' contact points being at right angles to Vthe contact movement and therefore in the most favorable direction. This arrangement has kinematic characteristics which are beneficial in a switch of this type, andy it also permits easy assembly in the present housing of general usefulness. It will also be noted that the operating force is in the contact making direction so that the contact pressure is upon operation momentarily increased before contact is broken by the snap movement.

it should be understood that the present disclosure is for the purpose of illustration only and that this invention includes all modications and equivalents which fall within the scope of the appended claims.

I claim:

l. An electric switch assembly comprising an elongated base formed of insulating material, a cover of insulating material fitting said base and defining with the base an enclosed cavity, holes extending in alignment through the base and the cover respectively, at each end and intermediate thereof, three internally threaded hollow rivets, one in each of said holes of said base, switch contact members fastened to said base within said cavity by the head means of respective rivets, and screws extending through said holes at said ends of the cover to engage the internal threads of the rivets in the corresponding holes of the base, for fastening the cover to the base.

2. Switch assembly according to claim l wherein a movable switch contact member is fastened to the rivet in one of said end holes of the base and an essentially stationary switch contact member is fastened to the rivet in one of the other holes of the base.

3. Switch assembly according to claim 1 wherein a movable switch contact member is fastened to the rivet in one of said holes at said ends of the base and two essentially stationary switch contact members are fastened to the rivets in the two other holes on either side of said movable member which contacts one or the other of said stationary members.

4. Switch assembly according to claim 3 wherein said movable contact member is a spring one end of which is fastened to said rivet in one of said holes at said ends,

whereas the other end can be moved between said stationary contact members.

5. Switch assembly according to claim 3 wherein said movable contact member is a snap switch element which includes an essentially rigid frame member extending from said end hole into the space between said stationary contact members, and a snap spring member for propelling said frame member between said stationary contact members.

6. Switch assembly according to claim 5 wherein said frame member is pivoted on one end of a compensating spring whose other end is fastened to said rivet in said end hole.

7. Switch assembly according to claim 5 wherein said snap spring member is pivoted on one end of a cmpensation spring whoseother end is fastened to said rivet in said end hole.

8. Switch assembly according to claim further comprising two actuator members extending through respective ones of said intermediate holes of cover and base, said snap spring member extending between the two actuator members, whereby deflection of the snap spring member by one of the actuator members propels it towards the other actuator member.

9. Switch assembly according to claim 5 further comprising an actuator member extending through one of said intermediate holes and a ,resilient stop member fastened to the other hole, said snap springmember extending between the actuator member 'and the stop member, whereby deflection of the snap spring member by the actuator member propels it towards the. stop member which vpropels it back towardsV the actuator member.

10. Switch assembly according to claim 1 wherein .a switch actuator extends through one of said intermediate holes.

11. Switch assembly according to claim 1 wherein a switch actuator extends through said intermediate hole of the cover, and a second actuator extends through the hollow rivet in said intermediate hole of the base.

12. Switch assembly according to claim 1, wherein said base has within said cavity three essentially parallel surfaces at three diiferent levels, the lowest and highest levels at said intermediate hole and one of said end holes respectively, for supporting with the head means of respective rivets two switch contact members, and the intermediate level at the other end hole for supporting with the head means of a rivet a switch contact member extending between the stationary contact members.

13. Switch assembly according to claim 1 further com prising terminal means held between the outside of said base and the head of at least one of said rivets.

14. Switch assembly according to claim l further comprising terminal means and a screw for holding the terminal means between its head and the head of one of said internally threaded rivets.

l5. Switch assembly according to claim 1 further comprising terminal strip means held between said cover and one 0f said screws.

16. Switch assembly according to claim 1 wherein said screws are studs screwed into said hollow rivets, and further comprising nuts for fastening said cover to said base, the studs extending beyond the cover for mounting purposes.

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17. Switch assembly according to claim 1 wherein said screws are made of insulating material whereby said cover is insulated from said base.

18. Switch assembly according to claim 1 wherein said base has on the outside recesses extending from said holes, and said hollow rivets have lugs fitting said recesses.

19. Switch assembly according to claim l, wherein said cover has a longitudinal groove containing the outside openings of said holes, for aligning accessories fitting said groove and mounted with screws through said holes.

20. An electrical switch comprising an elongated base formed of insulating material and having a cover defining with the base an enclosed cavity, three spaced hollow internally threaded rivets extending from said Vcavity through said base to the outer surface thereof, two sta' tionary contact carrying members fastened within the cavity to the base by the head means of the center rivet and one of the end rivets respectively, a movable contact carrying member fastened within the cavity to the base by the head means of other end rivet, screws engaging each of said end rivets for fastening said cover to said base, and an actuator mounted in said cover for operating said movable contact carrying member.

21. Switch according to claim 20 wherein two screws are of nonconducting material and extend through said cover to engage respectively the internal threads of each end to fasten the cover to the base, and three of said fastening screws are'ter'rninal screws each of which en`v gages the internal threads of a respective rivet at said outer surface of the base for connecting the switch to an external circuit. 1

22. An electric .switch assembly comprising an elongated base formed of insulating material, a cover of Vinsulating material ttiugf said base and defining with the base an enclosed cavity having three internal surfaces on different levels at each end and intermediate thereof, holes extending in alignment through the base and the cover respectively, each through a different level, three v internally threaded hollow rivets, one in each of said holes of said base, two essentially stationary switch contact members fastened to said base within said cavity between the head of a rivet and said surfaces at the higher and lower levels, a movable switch contact membe'.

fastened to said base within said cavity between the head of the third rivet and said surface at the intermediate level, and screws extending through said end holes of the cover to engage the internal threads of the rivets in the corresponding holes of the base, for fastening the cover to the base.

References Cited in the le of this patent UNITED STATES PATENTS 

